Thermally conductive polymer composition and articles made therefrom

Abstract

Polymer compositions are provided, and articles made therefrom. The polymer compositions comprise from 25 to 50 wt. % of a thermoplastic polymer; from 10 to 45 wt. % of a thermally conductive filler; from 15 to 30 wt. % of a carbon fiber; from 2 to 8 wt. % of a toughener; and less than 5 wt. % additives. The polymer composition is substantially free of glass fibers. The polymer compositions described herein surprisingly exhibit significantly improved thermal conductivity relative to analogous polymer compositions not comprising the toughener and/or in which the carbon fiber is replaced by glass fiber.

1 . A polymer composition comprising:
 from 25 to 50 wt. % of a thermoplastic polymer;   from 10 to 45 wt. % of a thermally conductive filler;   from 15 to 30 wt. % of a carbon fiber;   from 2 to 8 wt. % of a toughener; and   less than 5 wt. % additives;   
       wherein
 wt. % is based on the total weight of the polymer composition, 
 the polymer composition is substantially free of glass fibers, and 
 the through-plane thermal conductivity of the polymer composition is at least 1.5 W/(m·K). 
 
     
     
         2 . The polymer composition of  claim 1 , wherein the through-plane thermal conductivity of the polymer composition is at least 2 W/(m·K). 
     
     
         3 . The polymer composition of  any preceding claim , wherein the through-plane thermal conductivity of the polymer composition is at least 2.25 W/(m·K). 
     
     
         4 . The polymer composition of  any preceding claim , wherein the through-plane thermal conductivity of the polymer composition is at least 40% greater than an analogous polymer composition not comprising the toughener. 
     
     
         5 . The polymer composition of  any preceding claim , wherein the thermally conductive filler is an inorganic oxide or an inorganic nitride. 
     
     
         6 . The polymer composition of  any preceding claim , wherein the thermally conductive filler is boron nitride. 
     
     
         7 . The polymer composition of  any one of the preceding claims , wherein the thermoplastic polymer is selected from the group consisting of a poly(aryl sulfide), a polyamide, a poly(aryl ether sulfone), a poly(aryl ether ketone), a liquid crystal polymer, and a polyester. 
     
     
         8 . The polymer composition of  any one of the preceding claims , wherein the thermoplastic polymer is a poly(arylene sulfide). 
     
     
         9 . The polymer composition of  any one of the preceding claims , wherein the thermoplastic polymer is polyphenylene sulfide. 
     
     
         10 . The polymer composition of  any one of the preceding claims , wherein the thermoplastic polymer is a polyamide. 
     
     
         11 . The polymer composition of  any one of the preceding claims , wherein the toughener is selected from functionalized polymer backbones. 
     
     
         12 . The polymer composition of  claim 11 , wherein the polymer backbone of the toughener is selected from elastomeric backbones comprising polyethylenes and copolymers thereof; polybutenes; polyisoprenes; ethylene-propylene-rubbers (EPR); ethylene-propylene-diene monomer rubbers (EPDM); ethylene-acrylate rubbers; butadiene-acrylonitrile rubbers, ethylene-acrylic acid (EAA), ethylene-vinylacetate (EVA); acrylonitrile-butadiene-styrene rubbers (ABS), block copolymers styrene ethylene butadiene styrene (SEBS); block copolymers styrene butadiene styrene (SBS); core-shell elastomers of methacrylate-butadiene-styrene (MBS) type, or mixture of one or more of the above. 
     
     
         13 . The polymers composition of  claim 11 or 12 , wherein the toughener is a functionalized tougheners selected from the group consisting of terpolymers of ethylene, acrylic ester and glycidyl methacrylate, copolymers of ethylene and butyl ester acrylate; copolymers of ethylene, butyl ester acrylate and glycidyl methacrylate; ethylene-maleic anhydride copolymers; EPR grafted with maleic anhydride; styrene copolymers grafted with maleic anhydride; SEBS copolymers grafted with maleic anhydride; styrene-acrylonitrile copolymers grafted with maleic anhydride; ABS copolymers grafted with maleic anhydride. In some embodiments, the toughener is a terpolymer of ethylene, acrylic ester and glycidyl methacrylate, a copolymers of ethylene and butyl ester acrylate; and a copolymer of ethylene, butyl ester acrylate and glycidyl methacrylate. 
     
     
         14 . An article comprising the polymer composition of  any preceding claim . 
     
     
         15 . The article of  claim 14 , wherein the article is selected from the group consisting of an electronic device, an automobile, a motor, a battery, an LED, an electronic board, an electronic vehicle charging station, a vacuum or vacuum system or a component of any of these.